Method of making a lined carton



March 15, 1966 K. D. DOBLE, JR

METHOD OF MAKING A LINED CARTON Original Filed Aug. 27, 1962 I N VENTOR.

ATTORNEY United States latent O 3,240,131 METHOD OF MAKING A LINEDCARTQN Kendall D. Dohle, In, Hingham, Mass, assignor to Pneumatic Scale(Iorporation, Limited, Quincy, Mass., a corporation of MassachusettsOriginal application Aug. 27, 1962, Ser. No. 219,632, now Patent No.3,182,883, dated May 11, 1965. Divided and this application June 25,1963, Ser. No. 290,516 2 Claims. (Cl. 93-36.01)

This application is a division of my copending applica-- tion, SerialNo. 219,632, filed August 27, 1962, now US. Patent No. 3,182,883, issuedMay 11, 1965.

This invention relates to a method of making a lined carton.

The invention has for an object to provide a novel and improved methodof forming a lined carton characterized by a novel end closure adaptedto produce a strong and substantially leakproof lined carton.

A further object of the invention is to provide an improvement in thelined carton and method of making the same as illustrated and describedin the United States patent to John G. Vergobbi, No. 2,950,036, datedAugust 23, 1960.

With these general objects in view and such others as may hereinafterappear, the invention consists in the method of making the lined cartonas hereinafter described and particularly defined in the claims at theend of this specification.

In the drawings illustrating the preferred embodiment of the invention:

FIG. 1 is a plan view of a composite carton blank and lining sheet;

FIG. 2 is an end view illustrating a step in the sequence of wrappingthe composite blank about a mandrel;

FIG. 3 is a similar view showing the composite blank completely wrappedabout the mandrel providing a tubular structure open at both ends; and

FIGS. 4 and 5 are perspective views illustrating the sequence of formingthe end closure.

In general the present invention contemplates a novel lined cartonadapted to be produced at relatively high speeds on automatic cartonforming machines and whose structure is such as to provide a relativelystrong, tight and substantially leakproof lined carton. In accordancewith one feature of the present invention the present lined carton isformed from a composite blank comprising a prescored carton blank havingside and end wall panels and closing flaps, and a lining sheet securedto the carton blank so that in practice the composite blank may be feddirectly into the carton forming machine to perform simultaneous formingand folding operations on the carton blank and lining sheet. It will beapparent that such procedure eliminates the requirement of separatefeeding and folding apparatus for the lining sheet and the carton blankand is thus conducive to more economical production. In practice it ispreferred to arrange the lining sheet in offset relation to the cartonblank so that when the composite blank is wrapped about a mandrel orforming block the overlapping portions of each blank and sheet occur inspaced relation to form separate adhesively secured side seams.

In accordance with another feature of the present invention a novel endclosure or bottom closure is provided which includes an elongated liningbottom fold wherein opposed side walls of the extended lining are foldedinwardly and adhesively secured in overlapping relation, and the opposedend walls of the lining are folded outwardly to provide triangular endtabs coextensive with the bottom of the carton. In the illustratedembodiment of the invention the end closing flaps which areconventionally Patented Mar. 15, 1966 ice coextensive with the end wallpanels of the carton are omitted from the end wall panels and areinstead formed integrally with one of the side wall panel closing flaps.In practice the side flaps of the carton are folded down intooverlapping relation and adhesively secured to each other and to thelining bottom fold, whereupon the end closing flaps formed integrallywith the last folded side flap are folded upwardly together with thetriangular lining end tabs and adhesively secured against the end wallpanels of the carton. This structure of bottom fold in a lined cartonprovides a relatively strong and tight and substantially leakproofclosure in a rapid and efiicient manner. Furthermore, the present bottomclosure structure presents a smooth, even and more attractive bottomwall surface free of projections such as were formerly caused by the endflaps and lining tabs folded against the bottom wall. The present bottomclosure thus presents a substantially flush surface providing a flatbase free of projections by which a filled container may stand on endwith less likelihood of tipping over, and also provides uninterruptedend surfaces on which printed matter may 'be more efficiently andattractively applied.

In accordance with another feature of the present invention the liningsheet and the carton blank are preferably secured together by a singlerelatively narrow line of adhesive disposed in a medial portion of thecomposite blank longitudinally of and adjacent a marginal edge of a sidewall panel. In the formation of the present rectangular lined carton thecomposite blank is wrapped about a rectangular forming block by firstpresenting the intermediate side Wall panel, in which said line ofadhesive is disposed, against the bottom face of a horizontally extendedforming block. Thereafter, the extended portions of the composite blankare folded upwardly against the sides of the block and then inwardlyagainst the top of the block to present the marginal edges of the liningand the marginal edges of the outer blank into overlapping relation. Asa result the extended portions of the lining sheet and the carton blankon both sides of the adhesively secured portion which are free ofadhesive connections are free to move relative to each other during thefolding of the extended portions about the forming block whereby toprevent buckling of the lining sheet during the folding operation. Thisstructure of bottom fold in a lined carton provides a relatively strongand tight and substantially leakproof closure which may be formed in arapid and efficient manner.

Referring now to the drawings, 10 represents a composite carton blankand liner comprising a fiat prescored carton blank 12 and a liner sheet15 wherein the carton blank 12 may comprise any of the usual relativelystiff carton board materials and which is provided with side wall panels14, 16 and end wall panels 18, 20 provided with top and bottom closingflaps. The top closing flaps may comprise the usual side flaps 22, 24and end flaps 26, 28, each top closing flap being of a heightsubstantially equal to the width of the end wall panels 18, 20 whichcorresponds to the thickness of the assembled container. The bottomclosing flaps include a side flap 30 extended from the side wall panel14 which may also be equal in height to the thickness of the assembledcontainer. The side flap 30 is also provided with a pair of opposedlaterally extended end flaps 34, 36 formed integrally therewith andwhich may be of intermediate height as illustrated. A second andrelatively short side flap 32 extends from the side wall panel 16. Theend wall panels 18, 20 are free of closing flaps. As illustrated in FIG.1, the carton blank 12 is also provided with a relatively narrowmarginal sealing panel or flap 38 extended laterally from the end wallpanel 18.

In practice the flat prescored carton blank 12 is preferably providedwith pressure sensitive adhesive along selected portions of the innerface thereof prior to assembly with the liner, such adhesive being ofthe type which is non-adhering until pressure activated. As hereinshown, the side wall panel 16 is provided with a relatively narrow stripof pressure sensitive adhesive 45) along the marginal edge thereof foroverlapping sealing engagement with the outer face of the sealing flap38 during the formation of the lined carton. The bottom closing flaps,including the side flap 30 and its integral end flaps 34 and 36, areprovided with a pressure sensitive adhesive across the entire inner faceof the flap as indicated at 44, and the relatively short side flap 32 islikewise provided with a pressure sensitive adhesive across its entireinner face as indicated at 46. The inner face of the side wall panel 14is preferably provided with a relatively narrow liquid adhesive strip 42along a longitudinal marginal portion of the panel and spaced laterallya short distance from the score line 43 connecting the panel 14 to thepanel 20 as illustrated. The liquid adhesive is applied to the cartonblank before superimposing the lining sheet thereover to adhesivelysecure the lining sheet to the carton blank and serves as the onlyconnection between the blank and the lining sheet to maintain the blankand the sheet in composite relation during the subsequent folding of thecomposite structure to produce a lined carton.

The carton lining sheet which may comprise any of the usual or preferredrelatively thin and flexible lining materials comprises a rectangularsheet which may also be provided .with pressure sensitive adhesive alongselected portions of the inner face thereof prior to assembly with thecarton blank. As herein shown, the lining is provided with a pressuresensitive strip of adhesive 54 extended longitudinally adjacent themarginal side edge 56 thereof for overlapping sealing engagement withthe opposed marginal side edge 58 of the lining during subsequentformation of the lined carton. The lining sheet 15 is provided with asecond pressure sensitive adhesive strip 60 extended transverselyadjacent a portion of the lower marginal edge thereof for overlappingsealing engagement with an opposed extended lining portion during thesubsequent formation of the lining bottom closure.

In the production of the present lined carton the preformed carton blank12 is first provided with adhesive, as described, and thereafter arectangular sheet of lining paper, preferably withdrawn from a supplyroll thereof is provided with adhesive, severed to length and positionedon top of the carton blank and adhesively secured thereto by therelatively narrow adhesive strip 42 on the carton blank. As illustratedin FIG. 1, the lining sheet 15 is preferably placed on the carton blankin an offset position so that the marginal edge 56 defining one side ofthe lining sheet is offset inwardly from the adjacent marginal edge 57of the carton blank, and the opposed marginal edge 58 defining the otherside of the lining sheet extends beyond the adjacent marginal edge 59 ofthe carton blank. The upper marginal edge 62 of the lining sheet mayextend above the top closure flaps, as shown, and the lower marginaledge 64 of the sheet may and preferably will be spaced upwardly from thelower marginal edge of the carton blank.

The composite carton blank and liner 10 thus prepared may then beadvanced into operative relation to an elongated forming block ormandrel 66 which is rectangular in cross section, and the compositeblank is then wrapped about the forming block in the manner indicated inFIGS. 2 and 3 wherein the panel 14 and the associated lining is placedagainst the wide bottom face of the rectangular forming block 66, andthe extended portions of the composite 'blank and liner are foldedupwardly to present the end wall panels 18, and the associated liningportions against the narrow side walls of the block. The sealing flap 38and associated lining portion are then folded against the top face ofthe block, and the side wall panel 16 and associated lining portion arealso folded against the upper face of the block whereby to present themarginal edge 56 of the lining sheet in overlapping relation to themarginal edge 58 thereof, and whereby to present the marginal edge 57 ofthe carton blank in overlapping relation to the sealing flap 38.Pressure may then be applied along the spaced or offset overlappingportions of the carton blank and liner sheet, respectively, to effectadherence of the overlapped portions by virtue of the pressure sensitiveadhesive strips 54 and 40. It will be observed that in folding theextended portions of the composite carton blank and lining sheet aboutthe forming block from both sides of the sealing line 42 the unconnectedlining portions are free to move relative to the carton blank so as toprevent cramping or buckling of the lining sheet within the carton blankduring the folding operation.

The composite blank and liner thus wrapped about the forming block andsecured together along the overlapped marginal edges of the carton andthe lining forms a rectangular tubular structure open at both ends. Inpractice the composite blank is disposed relative to the forming blockso that the outer end of the block is aligned with the bottom score line68 of the carton blank whereby the bottom closing flaps and the adjacentportions of the lining extend beyond the end of the block in position tobe folded over the end of the block to form the bottom end closure.

Referring now to FIG. 4, the first step in the formation of the bottomend closure comprises folding of the extended lining portions to form anelongated fold having triangular end portions or tabs 70, 72 as shown inFIG. 4. This may be accomplished by folding the extended narrower endwall portions of the lining outwardly while simultaneously folding theextended wider side Wall portions of the lining inwardly intooverlapping relation, the overlapping portions of the liner being thensubjected to pressure to secure the same together by virtue of thepressure sensitive adhesive strip 60. Simultaneously therewith, orimmediately thereafter, the relatively narrow side flap 32 is foldeddown and secured to the folded down lining by pressure to set thepressure sensitive adhesive 46.

The next step in the formation of the bottom end closure comprisesfolding of the wider side flap 30 inwardly on top of the folded downlining and in overlapping relation to the folded down narrow side flap32 as shown in FIG. 5. Application of pressure against the side flap 30will effect adherence of the same to the lining and the side flap 32 byvirtue of the pressure sensitive adhesive 44. The integral end fiaps 34,36 are then folded upwardly together with the triangular tabs 70, 72 ofthe elongated lining fold against the end wall panels 16, 20,respectively, so that in the completed lined carton the end portions 70,72 of the lining are interleaved between the end wall panels and the endflaps 34, 36, respectively. Application of pressure will set thepressure sensitive adhesive to secure the end flaps 34, 36 in theirfolded position. The lined carton thus produced may then be strippedfrom the forming block and transferred to a conveyor for delivery tocarton filling and closing mechanism.

From the above description it will be seen that the present lined cartonmay be economically produced in a rapid and efiicient manner, wherein apreformed composite carton blank and lining sheet may be introduced tothe package forming machine, thus eliminating separate feeding stationsfor the lining sheet and the carton blank. It will also be observed thatthe novel bottom end closure wherein the extended triangular liningportions 79, 72 are interleaved between the end wall panels and theirrespective end flaps formed integrally with the last folded side flapprovides a strong and substantially leakproof end closure having asubstantially flush bottom free of projections. The preapplied adhesivestrips described herein as pressure sensitive to'effect adherence maycomprise any of the commercially available adhesives including the heatand pressure sensitive type of adhesive.

\Vhile the preferred embodiment of the invention has been hereinillustrated and described, it will be understood that the invention maybe embodied in other forms within the scope of the following claims.

Having thus described the invention, what is claimed is:

1. The steps in the method of forming a lined carton on a rectangularforming block which consists in adhesively securing a medial portion ofa lining sheet to a medial portion only of a prescored carton blankhaving opposed side and end wall paneis and having two opposed bottomclosure side fiaps wherein one of said side flaps is provided with twoopposed end closure flaps formed integrally therewith, said end wallpanels being free of bottom closure flaps and said lining sheetincluding wall portions at the bottom thereof that at least partiallyoverlie said end closure flaps, the remainder of the sheet on both sidesof said medially secured portion being free of the carton blank, thenWrapping the composite blank about the forming block starting bypresenting said medial portion against one face of the block andprogressively folding adjacent adhesive-free portions of the compositeblank on both sides of said medial portion against successive adjacentfaces of the block to present the op posed and unsecured marginal edgesin overlapping rela tion, the unsecured portions of the lining sheetbeing free to move lengthwise relative to the carton blank during thewrapping operation, adhesively sealing said overlapping portions toprovide a tubular structure, forming a lining bottom closure from saidoverlying bottom lining portions having laterally extended triangulartabs while supported on the block, said tabs being substantially smallerin area than said end closure flaps, folding the bottom closure sideflaps into overlapping relation and adhesively securing the same and topresent the integral end flaps parallel to and in contiguous engagementwith said laterally extended triangular tabs, and then folding theopposed integral end flaps together with said triangular end tabsagainst opposed end wall panels and adhesively securing the same wherebyto provide a smooth and uninterrupted surface on the bottom of thecarton free of underlying end closure flaps and triangular lining tabs.

2. The steps in the method of forming a lined carton on a rectangularforming block which consists in adhesively securing a lining sheet to aprescored lining blank having opposed side and end wall panels andhaving two opposed bottom closure side flaps wherein one of the sidewall bottom flaps is relatively short in length and the other side wallbottom flap is of a width equal to the thickness of the carton isprovided with two opposed end closure flaps formed integrally therewith,said end wall panels being free of bottom closure flaps and said liningincluding wall portions at the bottom thereof that at least partiallyoverlie said end closure flaps, Wrapping the composite blank about theforming block to present the opposed marginal edges thereof inoverlapping marginal edge relation, adhesively securing said overlappingportions to provide a tubular structure, folding inwardly two opposedside Wall portions at the bottom of the lining and their adjacent bottomclosing side flaps and adhesively securing the same, said bottom closingoperation providing laterally extended triangular lining end tabportions which are substantially smaller in area than said end closureflaps and presenting the integral end closure flaps parallel to and incontiguous engagement with said triangular end tabs, and then foldingsaid opposed end flaps together with said triangular end tabs againstthe adjacent end wall panels and adhesively securing the same whereby toprovide a smooth and uninterrupted bottom closure free of underlying endclosure portions.

References Cited by the Examiner UNITED STATES PATENTS 2,776,607 1/1957Fischer et al 9336.6 2,950,036 8/1960 Vergobbi 9336.1 X 2,983,421 5/1961Turpin 229l4 X FRANK E. BAILEY, Primary Examiner.

BERNARD STICKNEY, Examiner.

1. THE STEPS IN THE METHOD OF FORMING A LINED CARTON ON A RECTANGULARFORMING BLOCK WHICH CONSISTS IN ADHESIVELY SECURING A MEDIAL PORTION OFA LINEAR SHEET TO A MEDIAL PORTION ONLY OF A PRESCORED CARTON BLANKHAVING OPPOSED SIDE AND END WALL PANELS AND HAVING TWO OPPOSED BOTTOMCLOSURE SIDE FLAPS WHEREIN ONE OF SAID SIDE FLAPS IS PROVIDED WITH TWOOPPOSED END CLOSURE FLAPS FORMED INTEGRALLY THEREWITH, SAID END WALLPANELS BEING FREE OF BOTTOM CLOSURE FLAPS AND SAID LINING SHEETINCLUDING WALL PORTIONS AT THE BOTTOM THEREOF THAT AT LEAST PARTIALLYOVERLIE SAID END CLOSURE FLAPS, THE REMAINDER OF THE SHEET ON BOTH SIDESOF SAID MEDIALLY SECURED PORTION BEING FREE OF THE CARTON BLANK, THENWRAPPING THE COMPOSITE BLANK ABOUT THE FORMING BLOCK STARTING BYPRESENTING SAID MEDIAL PORTION AGAINST ONE FACE OF THE BLOCK ANDPROGRESSIVELY FOLDING ADJACENT ADHESIVE-FREE PORTIONS OF THE COMPOSITEBLANK ON BOTH SIDES OF SAID MEDIAL PORTION AGAINST SUCCESSIVE ADJACENTFACES OF THE BLOCK TO PRESENT THE OPPOSED AND UNSECURED MARGINAL EDGESIN OVERLAPPING RELATION, THE UNSECURED PORTIONS OF THE LINING SHEETBEING FREE TO MOVE LENGTHWISE RELATIVE TO THE CARTON BLANK DURING THEWRAPPING OPERATION, ADHESIVELY SEALING SAID OVERLAPPING PORTIONS TOPROVIDE A TUBULAR STRUCTURE, FORMING A LINING BOTTOM CLOSURE FROM SAIDOVERLYING BOTTOM LINING PORTIONS HAVING LATERALLY EXTENDED TRIANGULARTABS WHILE SUPPORTED ON THE BLOCK, SAID TABS BEING SUBSTANTIALLY SMALLERIN AREA THAN SAID END CLOSURE FLAPS, FOLDING THE BOTTOM CLOSURE SIDEFLAPS INTO OVERLAPPING RELATION AND ADHESIVELY SECURING THE SAME AND TOPRESENT THE INTEGRAL END FLAPS PARALLEL TO AND IN CONTIGUOUS ENGAGEMENTWITH SAID LATERALLY EXTENDED TRIANGULAR TABS, AND THEN FOLDING THEOPPOSED INTEGRAL END FLAPS TOGETHER WITH SAID TRIANGULAR END TABSAGAINST OPPOSED END WALL PANELS AND ADHESIVELY SECURING THE SAME WHEREBYTO PROVIDE A SMOOTHAND UNINTERRUPTED SURFACE ON THE BOTTOM OF THE CARTONFREE OF UNDERLYING END CLOSURE FLAPS AND TRIANGULAR LINING TABS.